Efficient architecture for interfacing redundant devices to a distributed control system

ABSTRACT

A system and method for interfacing redundant devices to a distributed control system, includes a first and second redundant field bus modules communicably coupled to the distributed control system and to one another via Ethernet switches. A pair of redundant field devices are coupled to the Ethernet switches, one FD having a floating IP address. The FBMs adopt respective roles as master FBM and tracker FBM, so that the master FBM is configured to capture data from the one FD using the floating IP address, and to pass any data changes periodically to the tracker FBM, through the Ethernet switches. The master FBM is configured to point to the other field device in the event the other field device has assumed the floating IP address. The FBMs are configured to switch roles in the event communication is disrupted between the master FBM and the FD having the floating IP address.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 61/045,339 entitled Efficient Architecture for Interfacing RedundantDevices to a Distributed Control System, filed on Apr. 16, 2008, thecontents of which are incorporated herein by reference in their entiretyfor all purposes.

BACKGROUND

1. Technical Field

This invention relates to control systems and, more particularly, tofault-tolerant methods and apparatus for process control.

2. Background Information

The terms “control” and “control systems” refer to the control of theoperational parameters of a device or system by monitoring one or moreof its characteristics. This is used to insure that output, processing,quality and/or efficiency remain within desired parameters over thecourse of time.

Control is used in a number of fields. Process control, for example, istypically employed in the manufacturing sector for process, repetitiveand discrete manufacture, though it also has wide application inelectric and other service industries. Environmental control findsapplication in residential, commercial, institutional and industrialsettings, where temperature and other environmental factors must beproperly maintained. Control is also used to monitor and control devicesused in the manufacture of various products, ranging, for example, fromtoasters to aircraft.

Control systems typically utilize field devices, including sensors andthe like, which are integrated into the equipment being controlled. Forexample, temperature sensors are usually installed directly on or withinthe articles, bins, or conduits that process, contain or transport thematerials being measured. Control devices such as valves, relays, andthe like, must also be integrated with the equipment whose operationsthey govern.

Predictability is among the key requirements of any control device. Afluid sensor that even occasionally produces unreliable readings isunacceptable. Overengineering may insure better reliability; however, itoften results in devices that are too expensive or too large for wideapplication.

Redundancy is a well accepted alternative to overengineering. Ittypically involves using two or more standard control elements in placeof one. The duplicated units can be field modules, controllers or otherhigher-level elements in the control hierarchy.

Thus, for example, U.S. Pat. No. 4,347,563 discloses an industrialcontrol system in which redundant processing units serve as bus masters“of the moment,” monitoring status information generated by primaryprocessing units. If a redundant unit detects that a primary has becomefaulty while executing an application program, the redundant unit loadsthat program and takes over the primary's function.

U.S. Pat. No. 5,008,805, on the other hand, discloses a real timecontrol system in which “sender” and “listener” processors synchronouslystep through sequential schedules, with the sender controlling executionof events sent from a host. The listener monitors the sender and in theevent of fault, assumes the role of the latter, executing commandsomitted during the takeover interval.

A shortcoming of these and many other prior art redundancy schemes istheir imposition of undue computational or hardware overhead. U.S. Pat.No. 5,008,805, for example, has the disadvantage of requiring that thesender and listener operate in lock-step, necessitating common timinglines and up-front synchronization procedures.

The I/A Series process control systems, manufactured by the assigneehereof, represent a significant advance in this technology. They utilizea fault-tolerant architecture including a workstation which provides amonitoring and control interface for operations and maintenance staff.Control algorithms may be executed in one or more control processors(CPs), with control achieved via redundant fieldbus modules (FBMs) thatconnect to Field Devices (FDs), such as transmitters or ProgrammableLogic Controllers (PLCs), and sensors or valves associated with thephysical equipment to be operated. Various software packages providehistorical tracking of plant data, alarming capabilities, operatoraction tracking, and status of all stations on the process controlsystem network.

Each fieldbus module (FBM), for example, has a redundant, shadow(tracker) partner. The tracker is configured to assume the primary‘master’ role, such as in the event of a failure or other error, topermit it to be replaced or updated without taking the system off-line.

In this approach, each of the redundant FBMs communicates with, andcaptures identical data from, redundant Field Devices (FDs).

While the prior art techniques have proven effective to date, the everincreasing complexity of control systems render those techniquesproblematic. For example, the data stream between the Master FD and eachFBM tends to be of relatively large bandwidth, due to the nature of theoften complex protocols used by the process control network. Thisbandwidth is even larger due to the duplicate data being sent to bothFBMs in order to ensure full redundancy. Response time by the Master FDis thus often undesirably slow due both to this relatively large amountof traffic, and because the Master FD needs to process requests fromboth FBMs. In addition, use of Floating or Dynamic IP Addresses at theFD level also adds complexity to this overall approach.

Thus, a need exists for an improved fault-tolerant approach for processcontrol that addresses the foregoing drawbacks.

SUMMARY

In one aspect of the invention, a system for interfacing redundantdevices to a distributed control system, includes a first field busmodule (FBM) communicably coupled to the distributed control system, thefirst FBM coupled to a first Ethernet switch; a second FBM communicablycoupled to the distributed control system, the second FBM coupled to asecond Ethernet switch; with the first and second FBMs communicablycoupled to one another by the Ethernet switches. A pair of field devices(FDs) are coupled to the Ethernet switches, the FDs being redundant ofone another, wherein data is synchronized therebetween. One FD of thepair has a floating IP address, and the first and second FBMs areredundant of one another, so that data is synchronized therebetweenthrough the first and second Ethernet switches. The first and secondFBMs are configured to adopt respective roles as master FBM and trackerFBM, so that the master FBM is configured to capture data from the oneFD using the floating IP address, and to pass any data changesperiodically to the tracker FBM, through the Ethernet switches. Theother FD of the pair is configured to assume the floating IP address inthe event of a failure of the one FD. The master FBM is configured topoint to the other field device in the event the other field device hasassumed the floating IP address. The first and second FBMs areconfigured to switch roles in the event communication is disruptedbetween the master FBM and the FD having the floating IP address. Thesystem is redundant so that data is preserved in the event of failure ofany one of the FBMs and FDs and/or switches.

In another aspect of the invention, a method of interfacing redundantdevices to a distributed control system includes communicably coupling afirst field bus module (FBM) to the distributed control system, couplingthe first FBM to a first Ethernet switch, communicably coupling a secondFBM to the distributed control system, coupling the second FBM to asecond Ethernet switch and communicably coupling the first and secondFBMs to one another by the Ethernet switches. A pair of field devices(FDs) are coupled to the Ethernet switches, the FDs being redundant ofone another, wherein data is synchronized therebetween, one FD of thepair having a floating IP address. The first and second FBMs areconfigured to be redundant of one another, wherein data is synchronizedtherebetween through the first and second Ethernet switches. Additionalsteps include configuring the first and second FBMs to adopt respectiveroles as master FBM and tracker FBM, wherein the master FBM isconfigured to capture data from the one FD using the floating IPaddress, and to pass any data changes periodically to the tracker FBM,through the Ethernet switches; configuring the other FD of the pair toassume the floating IP address in the event of a failure of the one FD;configuring the master FBM to point to the other field device in theevent the other field device has assumed the floating IP address; and

configuring the first and second FBMs to switch roles in the eventcommunication is disrupted between the master FBM and the FD having thefloating IP address. The system is thus redundant so that data ispreserved in the event of failure of any one of the FBMs and Fds and/orswitches.

The features and advantages described herein are not all-inclusive and,in particular, many additional features and advantages will be apparentto one of ordinary skill in the art in view of the drawings,specification, and claims. Moreover, it should be noted that thelanguage used in the specification has been principally selected forreadability and instructional purposes, and not to limit the scope ofthe inventive subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is schematic diagram of a pair of process control field devicesand a pair of field bus modules in accordance with an embodiment of thepresent invention;

FIG. 2 is a view similar to that of FIG. 1, of an alternate embodimentof the present invention; and

FIG. 3 is a view similar to that of FIGS. 1 and 2, of another embodimentof the present invention.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings that form a part hereof, and in which is shown byway of illustration, specific embodiments in which the invention may bepracticed. These embodiments are described in sufficient detail toenable those skilled in the art to practice the invention, and it is tobe understood that other embodiments may be utilized. It is also to beunderstood that structural, procedural and system changes may be madewithout departing from the spirit and scope of the present invention.The following detailed description is, therefore, not to be taken in alimiting sense, and the scope of the present invention is defined by theappended claims and their equivalents. For clarity of exposition, likefeatures shown in the accompanying drawings are indicated with likereference numerals and similar features as shown in alternateembodiments in the drawings are indicated with similar referencenumerals.

Where used in this disclosure, the term “computer” is meant to encompassa workstation, person computer, personal digital assistant (PDA),wireless telephone, or any other suitable computing device. A “fieldbus”is a digital, two-way, multi-drop communication link among intelligentmeasurement and control devices, and serves as a local area network(LAN) for advanced process control, remote input/output and high speedfactory automation applications.

Embodiments of the system and method of the present invention can beprogrammed in any suitable language and technology, including, but notlimited to: C++; Visual Basic; Java; VBScript; Jscript; BCMAscript;DHTM1; XML and CGI Hypertext Markup Language (HTML), Active ServerPages(ASP) and Javascript. Alternative versions maybe developed using otherprogramming languages. Any suitable database technology can be employed,including, but not limited to: Microsoft Access and IMB AS 400.

Referring to FIG. 1, a distributed control system 100 includes arepresentative embodiment of the present invention, in the form of aredundancy architecture using Field Bus Modules (FBMs) that communicatewith Field Devices (FDs) via Ethernet protocols. As shown, system 100includes redundant FBMs 10, 12, e.g., in a ‘Master’ and ‘Tracker’configuration, which are configured to each communicate with, andcapture data from, redundant FDs 14, 16.

Referring now to FIG. 2, system 100′ may include system 100, along witha workstation 13 which provides a monitoring and control interface foroperations and maintenance staff. Control algorithms may be executed inone or more control processors (CPs) 15, which are communicably coupledto the FBMs 10, 12 to achieve control via the FDs 14, 16, and sensors18, 20, associated with the physical equipment or process 22.

In particular embodiments, system 100′ includes an I/A Series processcontrol system, with CP 15 including an FCP 270 or ZCP Control Processoravailable from Invensys Systems, Inc., Foxboro, Mass., (“Invensys”). TheFBMs 10, 12 may be conventional FBM 233 control processors, alsoavailable from Invensys, which are modified in accordance with theteachings of the present invention.

The FDs 14, 16 are redundant of one another, in which data issynchronized therebetween, e.g., using a direct link 17. The FDs 14, 16are configured as ‘Master’ and ‘Tracker’ FDs, and may use Floating(e.g., Dynamic) IP Addresses to communicate with the network viaEthernet switches 24, 26, respectively. In the event of a failure of the‘Master’ FD, the ‘Tracker’ FD is configured to assume the floating IPaddress that had been used by the Master FD, so that either one of theredundant FBMs 10, 12 can point to, and capture data from, this new‘Master’ FD.

The FBMs 10, 12 are redundant of one another, being configured tocommunicate with one another to synchronize their data via theirEthernet switches 24, 26 (e.g., through Ethernet ports on each FBM). TheFBMs 10, 12 are configured to adopt respective roles as master FBM andtracker FBM, wherein the master FBM is configured to capture data fromthe master FD, e.g., using the floating IP address, and to pass any datachanges periodically to the tracker FBM, through the Ethernet switches.The FBMs 10, 12 are configured to switch roles in the eventcommunication is disrupted between the master FBM and the master FD.System 100 is thus redundant at both the FBM and FD levels, so that datais preserved in the event of failure of any one of the FBMs 10, 12 andFDs 14, 16.

The Tracker FBM is thus configured to receive data updates from theMaster FBM, rather than to obtain duplicate data directly from the FDs14, 16. This approach eliminates the need for additional resources inthe form of additional communication links between the redundant FBMs,by taking advantage of the unused portion of the relatively highbandwidth Ethernet links 24, 26 used by the FBMs.

In addition to communication between FBMs 10, 12, the Ethernet ports oneach FBM are also used for all communication between the FBMs and theFDs 14, 16. Thus, all FBM traffic, i.e., traffic between the redundantFBMs 10, 12, and between the FBMs and the FDs 14, 16, occurs ‘in band’,i.e., within the same network. This approach also eliminates the needfor two duplicate data streams from the master FD to each of the FBMs10, 12, to effectively halve the amount of data passing from the FDlevel to the FBM level. This reduction in data traffic tends to decrease(i.e., speed up) response time of the master FD, and otherwise freeresources of the FDs for other processing tasks, e.g., for relativelyfast data updates from the FD. This also generally provides theadditional benefit of field data updates reaching the CP more quickly,for relatively fast feedback and hence fast control of the overallsystem 100, 100′.

The overall amount of data being transferred to the Tracker FBM isrelatively low, since only changes in data are passed to the Tracker.Thus, the Tracker only needs to send relatively short messages to the FDto simply ensure that the communication link between the FBMs isoperational. The FBMs 10, 12 are also configured to effectively updatethe floating IP address of the FDs 14, 16 in real time, e.g., in theevent the Master FD fails and the floating IP address is assumed by theTracker.

In representative embodiments, the redundant FDs 14, 16 includeprogrammable logic controllers (PLCs), which in turn, may becommunicably coupled to any number of sensors 18, 20 associated with aprocess 22 (such as to measure flow through a conduit). As anon-limiting example, the FDs may be ControlLogix™ Programmable LogicControllers (PLCs) by Allen-Bradley Company, Inc. (RockwellInternational). (Suitable PLCs may also be available from Telvent Git,S.A.) These ControlLogix PLCs include the aforementioned ability tocommunicate with one another via a direct link 17, for redundant,‘Primary’ and ‘Secondary’ operation. They are also configured to useFloating (e.g., Dynamic) IP Addresses to communicate with the networkvia Ethernet switches 24, 26, and for the ‘Tracker’ to assume thefloating IP address. Moreover, each PLC is configured, upon assumptionof the ‘Master’ role, to broadcast its ownership of this IP address withits MAC address, to system 100. The redundant FBMs 10, 12 may thusconveniently receive this ownership information to point to, and capturedata from, this new ‘Master’ FD.

It should be noted that the tracker FBM may communicate directly withone or more of the FDs 14, 16, such as to obtain status informationand/or to otherwise ensure proper operation/readiness. However, thetracker FBM is configured to be synchronized with the master FBMindependently of any communication with the FDs 14, 16, i.e., all dataupdates are effected solely between the FBMs 10, 12, without any needfor the tracker FBM to receive data from the FD level. As discussedabove, this provision nominally eliminates any need for duplicate datatraffic from the FD level to the FBM level. Moreover, in variousembodiments as shown, the FBMs 10, 12 are synchronized independently ofany off-network (out of band) communication. In other words, the FBMs10, 12 are synchronized using their network switches 24, 26, without theneed for any direct links therebetween. Embodiments of the inventionthus enable the FBMs to be synchronized using only a single data streamfrom the FDs 14, 16 to the FBMs 10, 12. Various embodiments also effectthis FBM synchronization by sending only changes in data from the masterFBM to the tracker FBM. This provision serves to further reduce datatraffic on the network, to free up system resources for other tasks asdiscussed above.

It is also noted that in the event the tracker FD has assumed thefloating IP address to assume the role of master FD, the FBM may pointto this new master FD in real time. As used herein, the term ‘real time’refers to sensing and responding to external events nearlysimultaneously (e.g., within milliseconds or microseconds) with theiroccurrence, or sufficiently fast to enable the device to keep up with anexternal process (for example, sufficiently fast as to avoid losing datagenerated by the FDs).

Although the FBMs 14, 16 may be provided with multiple Ethernet portsand/or switches 24, 26, only a single Ethernet port is required tocommunicate with the FDs 14, 16 and with the tracker FBM.

Moreover, although the foregoing embodiments have been shown anddescribed as having a single pair of FBMs 10, 12 and FDs 14, 16, itshould be recognized that aspects of the present invention may beapplied to process control systems and apparatus of substantially anynumber of components. For example, a process control system in which theinvention is employed in a plurality of pairs of FDs 120, FBMs 122 andCPs 124 is illustrated in FIG. 3.

Referring now to the following Table I, a method of interfacingredundant devices to a distributed control system, in accordance withthe present invention, is shown and described.

TABLE I 200 Couple a first field bus module (FBM) to the distributedcontrol system 202 Couple the first FBM to a first Ethernet switch 204Couple a second FBM to the distributed control system 206 Couple thesecond FBM to a second Ethernet switch 208 Couple the first and secondFBMs to one another by the Ethernet switches 210 Couple a pair of fielddevices (FDs) to the Ethernet switches, the FDs being redundant of oneanother, so that data is synchronized therebetween, one FD of the pairhaving a floating IP address 212 Configure the first and second FBMs tobe redundant of one another, so that data is synchronized therebetweenthrough the first and second Ethernet switches 214 Configure the firstand second FBMs to adopt respective roles as master FBM and tracker FBM,so that the master FBM is configured to capture data from the one FDusing the floating IP address, and to pass any data changes periodicallyto the tracker FBM, through the Ethernet switches 216 Configure theother FD of the pair to assume the floating IP address in the event of afailure of the one FD 218 Configure the master FBM to point to the otherfield device in the event the other field device has assumed thefloating IP address 220 Configure the first and second FBMs to switchroles in the event communication is disrupted between the master FBM andthe FD having the floating IP address, so that data is preserved in theevent of failure of any one of the FBMs and FDs

At 200, a first FBM is communicably coupled to the distributed controlsystem. The first FBM is coupled to a first Ethernet switch at 202. At204, a second FBM is communicably coupled to the distributed controlsystem, and at 206, the second FBM is communicably coupled to a secondEthernet switch. At 208, the Ethernet switches are used to couple thefirst and second FBMs to one another. A pair of field devices (FDs) arecoupled to the Ethernet switches at 210, the FDs being redundant of oneanother, wherein data is synchronized therebetween, one FD of the pairhaving a floating IP address. At 212, the first and second FBMs areconfigured to be redundant of one another, so that data is synchronizedtherebetween through the first and second Ethernet switches. At 214, thefirst and second FBMs are configured to adopt respective roles as masterFBM and tracker FBM, so that the master FBM is configured to capturedata from the one FD using the floating IP address, and to pass any datachanges periodically to the tracker FBM, through the Ethernet switches.The other FD of the pair is configured, at 216, to assume the floatingIP address in the event of a failure of the one FD. The master FBM isconfigured 218 to point to the other field device in the event the otherfield device has assumed the floating IP address. The first and secondFBMs are configured 220 to switch roles in the event communication isdisrupted between the master FBM and the FD having the floating IPaddress, so that data is preserved in the event of failure of any one ofthe FBMs and FDs.

Optional aspects of this method are shown and described with respect toTable II.

TABLE II 224 Use programmable logic controllers (PLCs) used as theredundant FDs 226 Configure the FBMs to receive a notification that theother FD has assumed the floating point IP address, so that either ofthe FBMs can point to, and capture data therefrom 228 Synchronize thetracker FBM with the master FBM independently of any communication withthe FDs 230 Synchronize the tracker FBM and master FBM independently ofany off-network (out of band) communication therebetween 232 Synchronizethe tracker FBM and master FBM using only a single data stream from theFDs to the FBMs 234 Synchronize the tracker FBM by sending only changesin data from the master FBM 236 Configure, in real time, the master FBMto point to the other field device, in the event the other field devicehas assumed the floating IP address 238 Configure the master FBM to usea single Ethernet port for communication with the FD, and forcommunication with the tracker FBM 240 Couple a field control processor(FCP) to the first and second FBMs 242 Place a local communications linkbetween the first and second FDs for FD synchronization

Optionally, at 224, programmable logic controllers (PLCs) may be used asthe FDs. FBMs may be configured 226 to receive a notification that theother FD has assumed the floating point IP address, so that either ofthe FBMs can point to, and capture data therefrom. Moreover, the trackerFBM may be synchronized 228 with the master FBM independently of anycommunication with the FDs. The tracker FBM and master FBM may also besynchronized 230 independently of any off-network (out of band)communication therebetween. The tracker FBM and master FBM may also besynchronized 232 using only a single data stream from the FDs to theFBMs. At 234, the tracker FBM may be synchronized by sending onlychanges in data from the master FBM.

Additional optional aspects include configuring 236, in real time, themaster FBM to point to the other field device, in the event the otherfield device has assumed the floating IP address. The master FBM may beconfigured 238 to use a single Ethernet port for communication with theFD, and for communication with the tracker FBM. A field controlprocessor (FCP) may be coupled 240 to the first and second FBMs. A localcommunications link may be coupled 242 between the first and second FDsfor FD synchronization.

It should be understood that any of the features described with respectto one of the embodiments described herein may be similarly applied toany of the other embodiments described herein without departing from thescope of the present invention.

In the preceding specification, the invention has been described withreference to specific exemplary embodiments for the purposes ofillustration and description. It is not intended to be exhaustive or tolimit the invention to the precise form disclosed. Many modificationsand variations are possible in light of this disclosure. It is intendedthat the scope of the invention be limited not by this detaileddescription, but rather by the claims appended hereto.

1. A system for interfacing redundant devices to a distributed controlsystem, the system comprising: a first field bus module (FBM)communicably coupled to the distributed control system; the first FBMcoupled to a first Ethernet switch; a second FBM communicably coupled tothe distributed control system; the second FBM coupled to a secondEthernet switch; the first and second FBMs communicably coupled to oneanother by the Ethernet switches; a pair of field devices (FDs), coupledto the Ethernet switches; the FDs being redundant of one another,wherein data is synchronized therebetween; one FD of the pair having afloating IP address; the first and second FBMs being redundant of oneanother, wherein data is synchronized therebetween through the first andsecond Ethernet switches; the first and second FBMs configured to adoptrespective roles as master FBM and tracker FBM, wherein the master FBMis configured to capture data from the one FD using the floating IPaddress, and to pass any data changes periodically to the tracker FBM,through the Ethernet switches; the other FD of the pair configured toassume the floating IP address in the event of a failure of the one FD;the master FBM configured to point to the other field device in theevent the other field device has assumed the floating IP address; thefirst and second FBMs configured to switch roles in the eventcommunication is disrupted between the master FBM and the FD having thefloating IP address; wherein the system is redundant so that data ispreserved in the event of failure of any one of the FBMs, FDs orEthernet switches.
 2. The system of claim 1, wherein the redundant FDscomprise programmable logic controllers (PLCs).
 3. The system of claim2, wherein the other FD is configured to, upon assumption of thefloating point IP address, broadcast its ownership of the floating pointIP address to the FBMs, so that either of the FBMs can point to, andcapture data therefrom.
 4. The system of claim 3, wherein the trackerFBM is synchronized with the master FBM independently of anycommunication with the FDs.
 5. The system of claim 4, wherein thetracker FBM and master FBM are synchronized independently of anyoff-network (out of band) communication therebetween.
 6. The system ofclaim 5, wherein the tracker FBM and master FBM are synchronized usingonly a single data stream from the FDs to the FBMs.
 7. The system ofclaim 6, wherein the tracker FBM is synchronized by sending only changesin data from the master FBM.
 8. The system of claim 1, wherein themaster FBM is configured to point to the other field device in realtime, in the event the other field device has assumed the floating IPaddress.
 9. The system of claim 1, wherein the master FBM is configuredto use a single Ethernet port for communication with the FD, and forcommunication with the tracker FBM.
 10. The system of claim 1,comprising a field control processor (FCP) coupled to the first andsecond FBMs.
 11. The system of claim 1, comprising a localcommunications link disposed between the first and second FDs forsynchronizing the FDs.
 12. A method of interfacing redundant devices toa distributed control system, the system comprising: (a) communicablycoupling a first field bus module (FBM) to the distributed controlsystem; (b) coupling the first FBM to a first Ethernet switch; (c)communicably coupling a second FBM to the distributed control system;(d) coupling the second FBM to a second Ethernet switch; (e)communicably coupling the first and second FBMs to one another by theEthernet switches; (f) coupling a pair of field devices (FDs) to theEthernet switches, the FDs being redundant of one another, wherein datais synchronized therebetween, one FD of the pair having a floating IPaddress; (g) configuring the first and second FBMs to be redundant ofone another, wherein data is synchronized therebetween through the firstand second Ethernet switches; (h) configuring the first and second FBMsto adopt respective roles as master FBM and tracker FBM, wherein themaster FBM is configured to capture data from the one FD using thefloating IP address, and to pass any data changes periodically to thetracker FBM, through the Ethernet switches; (i) configuring the other FDof the pair to assume the floating IP address in the event of a failureof the one FD; (j) configuring the master FBM to point to the otherfield device in the event the other field device has assumed thefloating IP address; and (k) configuring the first and second FBMs toswitch roles in the event communication is disrupted between the masterFBM and the FD having the floating IP address; wherein the system isredundant so that data is preserved in the event of failure of any oneof the FBMs, FDs or Ethernet switches.
 13. The method of claim 12,wherein the redundant FDs comprise programmable logic controllers(PLCs).
 14. The system of claim 13, comprising configuring the FBMs toreceive a notification that the other FD has assumed the floating pointIP address, so that either of the FBMs can point to, and capture datatherefrom.
 15. The method of claim 14, comprising synchronizing thetracker FBM with the master FBM independently of any communication withthe FDs.
 16. The method of claim 15, comprising synchronizing thetracker FBM and master FBM independently of any off-network (out ofband) communication therebetween.
 17. The method of claim 16, comprisingsynchronizing the tracker FBM and master FBM using only a single datastream from the FDs to the FBMs.
 18. The method of claim 17, comprisingsynchronizing the tracker FBM by sending only changes in data from themaster FBM.
 19. The method of claim 12, comprising configuring, in realtime, the master FBM to point to the other field device, in the eventthe other field device has assumed the floating IP address.
 20. Themethod of claim 12, comprising configuring the master FBM to use asingle Ethernet port for communication with the FD, and forcommunication with the tracker FBM.
 21. The method of claim 12,comprising coupling a field control processor (FCP) to the first andsecond FBMs.
 22. The method of claim 12, comprising disposing a localcommunications link between the first and second FDs for FDsynchronization.
 23. An article of manufacture for interfacing redundantdevices to a distributed control system, said article of manufacturecomprising: a computer usable medium having a computer readable programcode embodied therein, said computer usable medium having: computerreadable program code for: (a) communicably coupling a first field busmodule (FBM) to the distributed control system; (b) coupling the firstFBM to a first Ethernet switch; (c) communicably coupling a second FBMto the distributed control system; (d) coupling the second FBM to asecond Ethernet switch; (e) communicably coupling the first and secondFBMs to one another by the Ethernet switches; (f) coupling a pair offield devices (FDs) to the Ethernet switches, the FDs being redundant ofone another, wherein data is synchronized therebetween, one FD of thepair having a floating IP address; (g) configuring the first and secondFBMs to be redundant of one another, wherein data is synchronizedtherebetween through the first and second Ethernet switches; (h)configuring the first and second FBMs to adopt respective roles asmaster FBM and tracker FBM, wherein the master FBM is configured tocapture data from the one FD using the floating IP address, and to passany data changes periodically to the tracker FBM, through the Ethernetswitches; (i) configuring the other FD of the pair to assume thefloating IP address in the event of a failure of the one FD; (j)configuring the master FBM to point to the other field device in theevent the other field device has assumed the floating IP address; and(k) configuring the first and second FBMs to switch roles in the eventcommunication is disrupted between the master FBM and the FD having thefloating IP address; wherein the system is redundant so that data ispreserved in the event of failure of any one of the FBMs, FDs orEthernet switches.